Method of forming dry-battery structures



June 26, 1928.

C. T. SCHUNK METHOD OF FORMING DRY BATTERY STRUCTURES Filed Jan. 14,1928 2 Sheets-Sheet l Zia-f W MIL Li Ii L J11 Lnnloi /iijam a June 26,1928.

C. T. SCHUNK METHOD OF FORMING DRY BATTERY STRUCTURES Filed Jan. 14,1928 2 Sheets-Sheet E] H0 24 Hot Patented June 26, 1928.

UNITED STATES PATENT OFFICE.

CARL '1. SCHUNK, OF LAKEWOOD, OHIO, ASSIGNOR TO THE PEERLESS PAPER BOXMANUFACTURING COMPANY, OF CLEVELAND, OHIO, A CORPORATION OF OHIO.

METHOD OF FORMING DRY-BATTERY STRUCTURES.

Application filed January 14, 1928. Serial No. 246,898.

This invention relates to a. method of making drv battery structures.such as the radio B-battery forming the subject matter of my co-pendingapplication tiled of even date herewith, Serial No. ii-ltLTttl.

The general object of the present invention is the provision of animproved method of making radio B-batteries of the character described,to the end that the parts thereof, including the line attaching clips,mav be easily, quickly and inexpensively assembled, and the completedbatteries neat and attractive in appearance, efficient and not likely toget out of order in use.

Further objects of the invention are in part obvious and in part willappear more in detail hereinafter.

In the drawings, which illustrate the battcry in its various stages ofassembly, Fig. 1 is a plan view of the tray in which are arranged theseries of battery cells; Fig. 2 IS a similar view with the compartmentforming partitions arranged in the tray; Fig. 3 is av view similar toFig. 2 and showing the cells arranged in said compartments; Fig. 4

is a front view of the supporting member for the line attaching clips;Fig. 5 is a similar view with the clips attached to said member; Fig. 6is a view similar to Fig. 3 but showing the cells connected to eachother and the line attaching clips, on their suporting member, connectedto three of said cells; Figs. 7 and 8 are respectively a plan View and aside elevation of the tray arranged in suitable clamping means, with asealing compound supplied to the tray; Fig. 9 is a view similar to Fig.7 but with the clamping means removed and the tray supplied with aremovable cover member; Fig. 10 is a perspective view of the trayenclosing casing, with the front end of said casing opened out: Fig. 11is a perspective view of the rear end portion of said casing; Fig. 12 isa side elevation of the casing with the tray partially insertedthereinto: Fig. 13 is a similar view with the tray entirely within thecasing and the front end of the casing in partially closed position: andFig. 14 is a perspective view of the front end portion of the completedbattery structure.

The battery structure made by the method of the present applicationincludes a tray in which are arranged a series of battery cells, saidtray being of any suitable shape, such as rectangular, and of anysuitable inexpensive material, such as light cardboard, prefcraby in asingle sheet. Said tray comprises a ottom 1, end walls 2 and 3, and sidewalls 4 and 5, the latter wall being provided with an edge extension 6for securement, such as by gluing, to the inner marginal surface of theend wall 2.

The top of the tray is therefore open to receive the partitions 9, whichmay be of any suitable inexpensive material, such as cardboard, saidpartitions being arranged in intersecting relation so as to form a plurality of cell receiving compartments 10. In the present embodiment ofthe invention, a battery structure having a capacity of felt tire voltsis to be made, so that nine intersecting partitions are provided to formcompartments for thirty cells 11 of one and a half volts each. Saidcells are of the usual form, having a cylindrical zinc casing 12 and acentrally disposed carbon rod 13, and are arranged in the compartments10 in upright position, as clearly indicated in the drawings.

These radio B-batteries are provided with three line attaching clips,each of which is connected to a. battery cell. These clips may be. ofany suitable type, and in the present embodiment of the invention,Pfanstock clips are illustrated each of which is provided with a lineattaching portion 15 and a rear end portion 16 for connection bysoldering to a battery cell.

The clip indicated by the reference character 18 is for connection to aradio A-battery and is therefore soldered to the zinc easing of thefirst cell; the clip indicated by the reference character 19 is forconnection to the plate member of a radio detector tube and is thereforesoldered to the carbon rod of the fifteenth cell, thereby obtaining anoutput of twenty-two and onehalf volts; and the clip indicated by thereference character 20 is for connection to either the plate member ofaladio detector tube or the plate member of a radio amplifying tube andis therefore soldered to the carbon rod of the thirtieth cell, therebyobtaining an output of forty-five volts.

In order to hold said clips in proper spaced relation for soldering tothe first, fifteenth and thirtieth cells, a supporting member 22 isprovided, which member is of substantially the same size as the trayside wall 4 against which it is secured. This supporting member 22 maybe of any suitable inexpensive material sutliciently rigid for thepurpose, such as medium weight cardboard. Three transverse slots 24 areprovided in said supporting member near one of its longer edges toreceive the rear or connecting end portions 16 of the clips, and similarslots correspondingly positioned are provided in the tray side wall 4.

In assembling the battery structure, the clips are first arranged in theslots of the supporting member 22 and the pro ectlng rear end portions16 of said clips are then pushed inwardly through the slots of the trayside wall 4, which places said end portions in proper position forconnection to their respective cells. The three clips are soldered totheir cells and the series of cells are interconnected by wires 27,soldered thereto, the carbon rod of each cell being connected to thezinc casing of an adjacent cell, as is usual.

After the cells have been interconnected by wires 2? and the clipsconnected to their respective cells,'as indicated in Fig. 6, the tray ofcells is arranged in suitable clamping means 30 and a suitable sealingcompound 31 is poured into the tray, more or less filling the spacesbetween partitions and cells and covering the tops of the cells to a.greater or less degree. A cover member 32, of any suitable material,such as corrugated cardboard, is then applied to the top of the tray,either while said tray is in the clamping means 30 or after it has beenremoved therefrom, the upper surface of said cover member beingpreferably substantially flush with the top of the tray.

The tray of battery cells thus formed is enclosed within a casing of anysuitable inexpensive material. such as light cardboard, preferably in asingle sheet and provided with the necessary fold lines to enable thecasing to be readily formed. Said casing includes a top portion 35, abottom portion 36 and two side portions 37 and 38, the latter portionbeing provided with an edge extension 39 for connection, by gluing orthe like, to the inner surface of the adjacent margin of thetop portion35. The casing side portions are each provided at their rear ends withan extension 40 and the casing top and bottom portions are each providedat theirrear ends with an extension 41. These four extensions form therear end wall of the casing and by gluing or otherwise suitablyconnecting the extensions 40 and 41 to each other, the rear end of thecasing is permanently closed. The extensions 40 are preferably arrangedinside of extensions 41, which are preferably of such size as togetheralmost completely close the rear end of the casing.

The casing bottom portion 36 is provided. at its front end with a ratherlarge extension which includes a portion 43 forming the front end wallof the casing. Said portion 43 is provided at each of its two sides witha sealing flap 44 and at its front free end with a sealing flap 45.These three flaps are adaptedto be inserted within the casing and gluedor otherwise suitably secured to the inner surface of the side and topportions of the casing as indicated in dotted lines, Fig. 14.Preferably, and as shown, the edge extension 39 .has its front endportion cut away, as at 46, so that it will not interfere with theinsertion into the casing of the sealing flap 45.

The front wall 43 of the casing is provided with three openings 48 sopositioned or spaced that when the front end of the casing is closed, asin Fig. 14, the line attaching portions 15 of the three clips 18, 19 and20 will project out through said openings and therefore be readilyaccessible for attachment of the lines or wires 49.

The several steps of the present method are therefore as follows:

The arrangement of the partitions 9 in the tray; the placing of abattery in each compartment formed by said partitions; the mounting ofthe line attaching clips under their supporting member: the assembly ofsaid supporting member, through the medium of said clips, with the sidewall 4 of the tray; the interconnecting by soldering of the cells andthe connection of said clip by soldering to three cells; the applicationof clamping means to the tray; the supply of the sealing compound; theapplication of the removable cover member: the removing of said clampingmeans (this step may precede the application of the cover memher); theinsertion of the tray within the enclosing casing: and the closing andsealing of the front end of the casing, leaving the attaching portionsofthe clips exposed for attachment of the wires 49.

\Vhat I claim is:

1. The method of making dry battery structures, consisting in arranginga plurality of cells in a container. mounting a pinrality of lineattaching clips upon a supporting member, and intcrconnccting said cellsbv wires soldered thereto and soldering said clips while upon saidmember to certain of said cells. thereby permanentlv as embling saidsupporting member with said clips.

2. The method of making dry battery structures. consisting in arranginga plurality of cells in a container having one of its walls providedwith a plurality of apertures. mounting a plurality of line attachingclips upon a supporting member with portions of said clips projectingfrom said member. inserting said projecting portions through theapertures in said casing wall. and soldering said clip portions tocertain of said cells.

3. The method of making dry batterv structures. consisting in arranginga. plurality of battery cells in a container having one of its wallsprovided with a plurality of apertures, inserting the connectio endportions of a plurality of line attac ling clips through a plurality ofopenings in a supporting member for said clips, with said clipconnecting portions projecting from said member, inserting saidprojecting clip por tions through the apertures of said cas'ng wall, andsoldering said inserted clip portions to certain of said battery cells.

4. The method of making dry battery structures, consisting in arranginga plura ity of battery cells in an open top tray having one of its sideWalls provided with a plurality of apertures, inserting the connectingend portions of a plurality of line attaching clips through a pluralityof openings in a supporting member for said clips, with said clipconnecting portions projecting from said member, inserting saidprojecting clip portions through the apertures of said tray wall,soldering said inserted clip portions to certain of said battery cells,and providing said tray with a cover member.

5. The method of making dry battery structures. consisting in arranginga plurality of intersecting partitions in a container so as to provide aseries of compartments in said container, arranging a battery cell ineach of said compartments. said container having one of its Wallsprovided with a plurality of apertures, inserting the connectingportions of a plurality of line attaching clips through openings in asupporting member for said clips, with said clip connecting portionsprojecting from said member, inserting said projecting clip portionsthrough the apertures of said container wall, and soldering saidinserted clip portions to certain of said cells, which secures saidsupporting member in assembled relation with said clips.

6. The method of making dry battery structures. consisting in arranginga plurality of battery cells in a container having one of its wallsprovided with a plurality of apertures, inserting the connectingportions of a plurality of line attaching clips through openings in asupporting member for said clips with said clip connecting portionsprojecting from said member. inserting said projecting clip portionsthrough the aperturcs of said container wall, soldering said insertedclip portions to certain of said buttery cells. which secures saidsupporting member in assembled relation with said clips. intcrcrmnectingsaid cells by wires rtlltltl'tl'l thereto, and pouring a scalingcompound into said container. so as to more or le s till the spacesbetween cells and cover said cells to a greater or less degree.

7. The method of making drv batterv structures, consisting in arranginga plurality of battery cells in an open top container having one of itsside walls provided with a lurality of apertures, inserting theconnectmg portions of a plurality of line attaching clips throughopenings in a supporting member for said clips, with said clipconnecting portions projecting from said member, inserting saidpro'ecting clip portions through the apertures 0 said container wall,soldering said inserted clip portions to certain of said battery cells,which secures said supporting member in assembled relation with saidclips, interconnecting said cells by wires soldered thereto, pouring asealing compound into said container, so as to more or less fill thespaces between cells and cover said cells to a greater or less degree,and applying a cover member to said container.

8. The method of making dry batter structures, consisting in arranging aplura ity of battery cells in a container having one of its wallsprovided with a plurality of apertures, inserting the connectingportions of a pluralit of line attaching clips through openings in asupporting member for said clips, with said cli connecting portionsprojectin from sai member, inserting said projecting clip portionsthrough the apertures of said container wall, soldering said insertedclip portions to certain of said battery cells, which secures said suporting member in assembled relation wit 1 said clips, interconnectingsaid cells by wires soldered thereto, and placing the aforementionedparts in an enclosingicasing.

9. The method of making dry battery structures, consisting in arranginga plurality of battery cells in a container having one of its wallsprovided with a plurality of apertures, inserting the connectingportions of a plurality of line attaching clips through openings in asupporting member for said clips, with said clip connecting portionsprojecting from said member, inserting said projecting clip portionsthrough the apertures of said container wall, soldering said insertedclip portions to certain of said battery cells, which secures saidsupporting member in assembled relation with said clips, interconnectingsaid cells by wires soldered thereto, and placing the aforementionedparts in an enclosing casing provided with a plurality of openings inone of its walls to permit portions of said clip to projecttherethrough.

10. The method of making dry battery structures, consisting in arranginga plurality of battery cells in a container having one of its wallsprovided with a plurality of apertures. inserting the connectingportions of a plurality of line attaching clips through openings in asupporting member for said chps. with said clip connecting portionsprojecting from said member, inserting said projecting clip portionsthrough the apertures of said container wall, soldering said insertedclip portions to certain of said battery cells, which secures saidsupporting member in assembled relation with said clips, interconnectingsaid cells by wires soldered thereto, and inserting the aforementionedparts in an enclosing casing having all but one of its walls permanentlycloseth said one \\'all being openable to permit the insertion of saidparts and being provided with openings to permit portions of said clipsto project therethrough.

11. The method of making dry battery structures. consisting in arranginga plurality of battery cells in an open top container having one of itsside walls provided with a plurality of apertures. inserting theconnecting portions of a plurality of line attaching clips throughopenings in a support ing member for said clips, with said clipconnecting portions pro1ecting from said member, inserting saidprojecting clip portions through the apertures of said container wall,soldering said inserted clip portions to certain of said battery cells,which secures said sup iiorting member in assembled relation with saidclips, interconnecting said cells by Wires soldered thereto, applyingconfining means to said container, and pouring a sealing compound intosaid container so as to more or less till the spaces between cells andcover said cells to a greater or less degree.

In testimony whereof I hereby aflix my signature.

CARL T. SCHUNK.

DISCLAIMER.

Mrrrnon or FORMING DRY-BATTERY r 'rmrc'rinuas. Patent dated June 26,1928. Disclaimer tiled September 24, 1928, by the patentee, assignee,ThePeerZess Paper Bottrllmmfacturing Company,

concurring.

Hereby enters this disclaimer to all of the claims of said patent, towit:

Claims 1 to 11, inclusive. 1 fiicz'a/ Gazette, October 9, 1928.]

apertures of said container wall, soldering said inserted clip portionsto certain of said battery cells, which secures said supporting memberin assembled relation with said clips, interconnecting said cells bywires soldered thereto, and inserting the aforementioned parts in anenclosing casing having all but one of its walls permanently closethsaid one \\'all being openable to permit the insertion of said parts andbeing provided with openings to permit portions of said clips to projecttherethrough.

11. The method of making dry battery structures. consisting in arranginga plurality of battery cells in an open top container having one of itsside walls provided with a plurality of apertures. inserting theconnecting portions of a plurality of line attaching clips throughopenings in a support ing member for said clips, with said clipconnecting portions pro1ecting from said member, inserting saidprojecting clip portions through the apertures of said container wall,soldering said inserted clip portions to certain of said battery cells,which secures said sup iiorting member in assembled relation with saidclips, interconnecting said cells by Wires soldered thereto, applyingconfining means to said container, and pouring a sealing compound intosaid container so as to more or less till the spaces between cells andcover said cells to a greater or less degree.

In testimony whereof I hereby aflix my signature.

CARL T. SCHUNK.

DISCLAIMER.

Mrrrnon or FORMING DRY-BATTERY r 'rmrc'rinuas. Patent dated June 26,1928. Disclaimer tiled September 24, 1928, by the patentee, assignee,ThePeerZess Paper Bottrllmmfacturing Company,

concurring.

Hereby enters this disclaimer to all of the claims of said patent, towit:

Claims 1 to 11, inclusive. 1 fiicz'a/ Gazette, October 9, 1928.]

